Chapter 1 Technical Administration

• Maintenance Categories
• Maintenance Scheduling
• Figure 1-1.—Sample preventive maintenance inspection schedule.
• Maintenance Inspections
• PM Record Cards
• Figure 1-3.—Vehicle/Construction Equipment PM Record Card, NAVFAC Form 11240/6.
• Repair Orders
• Figure 1-5.—Shop Repair Order Continuation Sheet.
• Figure 1-6.—Equipment Repair Order (ERO), NAVFAC 11200/41.
• Figure 1-7.—Equipment Repair Order (ERO) Block Codes, NAVFAC 11200/41.
• Figure 1-8.—Equipment Repair Order (ERO) Continuation Sheet, NAVFAC 11200/41A.
• Figure 1-9.—Equipment Repair Order (ERO) Work Sheet, NAVFAC 11200/41B.
• Figure 1-10.—Equipment Repair Order (ERO) Log
• Equipment History Jackets
• Figure  1-11.—DoD  Property  Record,  DD  Form  1342.
• Figure 1-13.—Time card.
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• Levels
• Figure 1-14.—Component identification group numbers (CIDs).
• Technical Manuals
• Requesting Spare Parts
• Figure 1-16.—Non-NSN Requisition, NAVSUP Form 1250-2.
• Repair Parts Control
• Figure 1-17.—DTO Log.
• Repair Parts Summary Sheet
• Figure 1-19.—DTO Information Sheet.
• Figure  1-20.—DD  Form  1348-1.

Chapter 2 Principles of an Internal Combustion Engine

• Development of Power
• Four-Stroke-Cycle Engine
• Figure 2-5.—Four-stroke cycle in a gasoline engine.
• Two-Stroke-Cycle Engine
• Figure 2-6.—Strokes and events in a four-stroke-cycle diesel engine.
• Figure 2-7.—Strokes and events in a two-stroke-cycle diesel engine cylinder.
• Classification of Engines
• Multiple-Cylinder Engines
• Arrangement of Cylinders
• Arrangement of Valves
• Figure 2-14.—T-head engine.
• Engine Measurements and Performance
• Figure   2-18.—Horsepower.
• Figure  2-20.—Prony  brake.
• Fire 2-22.—Demonstrating volumetric efficiency.
• Thermal Efficiency
• Linear Measurements
• Engine Performance
• Figure  2-26.—Typical  valve  timing  diagrams.
• Figure  2-28.—Valve  opening  duration.
• Figure 2-31.—Ignition timing.

Chapter 3 Construction of an Internal Combustion Engine

• FFigure 3-1.—Cylinder block and components.
• Figure 3-2.—Requirements of a cylinder.
• Figure  3-4.—Cylinder  sleeves.
• Figure 3-5.—Cylinder sleeve casualties.
• Figure 3-8.—Aircooled crankcase.
• Cylinder  Head
• Figure  3-11.—Combustion  chambers.
• Figure  3-13.—Cylinder  head  sealing.
• Exhaust Manifold
• Figure 3-15.—Typical intake manifold.
• Gaskets
• Moving Parts of an Engine
• Figure 3-20.—Synthetic rubber oil seals.
• Piston Assembly
• Figure 3-23.—The parts of a piston.
• Figure 3-25.—Controlling piston expansion.
• Figure 3-26.—Cam-ground piston action.
• Figure 3-29.—Piston pin.
• Figure 3-31.—Purpose of piston rings.
• Figure 3-32.—Types of piston rings.
• Figure 3-35.—Ring gap variations.
• Connecting Rods
• Crankshaft
• Figure  3-40.—Crankshaft  construction.
• Figure 3-41.—Crankshaft throw arrangements.
• Figure 3-43.—Typical insert bearing installation.
• Vibration Damper
• Valve and Valve Mechanisms
• Camshaft
• Figure 3-48.—Hydraulic tappets.
• Valve  and  Valve  Seats
• Valve  Guides
• Figure  3-54.—Valve  rotators.
• Figure 3-56.—Valve-refacing machine.
• Valve Guide Service
• Figure 3-59.—Puller used in removing valve seat inserts.
• Rocker Arm Service
• Timing Gears (Gear Trains)
• Engine Bearings
• Bearing Lubrication
• Bearing Characteristics
• Engine Adjustment and Testing
• Valves  in  Block
• Compression Test
• Vacuum Gauge Test
• Cylinder Leakage Test
• Cylinder Leakage Test - Continued

Chapter 4 Gasoline Fuel Systems

• Air-Fuel Ratio
• Gasoline Fuel System Components
• Fuel  Tank
• Fuel  Gauges
• Figure 4-5.—Thermostatic fuel gauge: self-regulating.
• Fuel Filters
• Fuel Pump
• Figure 4-9.—Fuel filter elements.
• Figure 4-10.—Mechanical positive fuel pump installation.
• Figure 4-11.—Mechanical nonpositive fuel pump.
• Figure 4-13.—Bellows-type electric fuel pump.
• Fuel Lines and Hoses
• Air Cleaner
• Principles of Carburetion
• Figure 1-17.—Example of atomization.
• Carburetor
• Float  System
• Idle System
• Figure 4-23.—Diaphragm accelerator pump.
• High-Speed System
• Figure 4-26.—Mechanically operated metering rod.
• Full-Power System
• Choke System
• Figure 4-29.—Manual choke system.
• Figure 4-34.—Engine coolant heated choke.
• Figure 4-36.—Exhaust-manifold heat-tube choke.
• Carburetor Accessories
• Figure 4-40.—Antidieseling solenoid operation.
• Computer Controlled Carburetors
• Carburetor Troubles
• Gasoline Fuel Injection Systems
• Figure 4-43.—Mechanical-timed injection.
• Figure 4-44.—Electronic-timed injection.
• Timed Fuel Injection Systems - Continued
• Continuous Fuel Injection Systems
• Throttle Body Injection System
• Exhaust and Emission Control Systems
• Exhaust Manifold
• Figure 4-48.—Manifold heat control valve.
• Catalytic Converters
• Air Injection System
• Figure 4-51.—Air injection system.
• Figure 4-52.—PCV system.
• Exhaust gas Recirculation System
• Fuel Evaporation Control System
• Figure 4-54.—Fuel evaporization system.
• Fuel Evaporation Control System - Continued

Chapter 5 Diesel Fuel Systems

• Figure 5-1.—Comparison of sequence of events in diesel and gasoline four-cycle engines.
• Diesel Fuel Oil Grades
• Viscosity
• Open Combustion Chamber
• Turbulence Chamber
• Figure  5-5.—Spherical  chamber.
• Governors
• Types of Governors
• Figure 5-6.—Mechanical (centrifugal) governor.
• Hydraulic  Governors
• Electronic Governors
• Diesel Fuel System Components
• Water   Separators
• Methods of Injection
• Catterpillar Fuel Systems
• Figure 5-10.—Sleeve metering barrel and plunger assembly.
• Governor Action
• Automatic Timing Advance Unit
• Transfer Pump
• Distributor-Type Fuel Systems
• Figure 5-14.—Transfer pump.
• Figure 5-15.—Rotor in charge position.
• Injection Pump Accessories
• Governor
• Detroit Diesel Unit Injection Systems
• Figure 5-23.—Diagram of typical Detroit diesel fuel system.
• Fuel Pump
• Injectors
• Injector Timing
• Equalizing Injectors
• Governor
• Cummins Diesel Fuel Systems
• Figure 5-29.—Pressure-time (PT) gear pump.
• Injectors
• Celect System
• Figure 5-30.—Pressure-time injector operation.
• Celect System - Continued
• Celect System Operation
• Figure 5-31.—Metering and distributing fuel pump assembly-left sectional view.
• American Bosch Fuel Injection Systems
• Figure 5-33.—Fuel intake flow diagram.
• Types of Nozzles
• Figure 5-38.—Fuel density compensator.
• Superchargers and Turbochargers
• Figure 5-39.—Centrifugal supercharger.
• Turbochargers
• Turbo  Lag
• Cold Weather Starting
• Ether
• Diesel Fuel System Maintenance
• General Troubleshooting
• Quick Injector Misfire Check
• Quick Injector Misfire Check - Continued

Chapter 6 Cooling and Lubricating Systems

• Air-Cooled Systems
• Fan and Shroud
• Liquid-Cooled System
• Radiator
• Radiator Hoses
• Water Pump
• Fan and Shroud
• Figure  6-9.—Variable  pitch  fan.
• Water  Jacket
• Figure 6-11.—Pellet-type thermostat.
• Figure   6-12.—Blocking-bypass   thermostat.
• Expansion (Recovery) Tank
• Temperature Gauge and Warning Light
• Flushing the System
• Coolign Systems Tests
• Combustion Leak Test
• Service and Repair of Cooling System Components
• Hoses
• Radiator and Pressure Cap
• Engine Lubricating Systems
• Purposes of Lubrication
• Figure 6-19.—Sources of oil contamination.
• Lubricating (Oil) System Components
• Oil Level Gauge
• Figure 6-22.—Gear-type oil pump.
• Oil Pickup and Strainer
• Figure 6-24.—Oil filters.
• Figure 6-25.—Filter system configurations.
• Oil Pressure Warning Light
• Oil Temperature Regulator
• Types of Lubricating Systems
• Force Feed
• Lubricating System Problem Diagnosis
• Lubricating System Maintenance
• Pressure Relief Valve Service
• Pressure Relief Valve Service - Continued

Appendix I Glossary

• Appendix I - Continued
• Appendix I - Continued
• Appendix I - Continued
• Appendix I - Continued
• Appendix I - Continued
• Appendix I - Continued
• Appendix I - Continued
• Appendix I - Continued
• Appendix I - Continued
• Appendix I - Continued

Appendix II Answer Key

• Appendix II - Continued
• Appendix II - Continued
• Appendix II - Continued
• Appendix II - Continued

Appendix III - References Used to Develop This Traman

Index

• Index - Continued
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Assignment Questions

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